How to reinforce rear hatch cover?

[mickjetblue]

I could use some tips on how to reinforce the rear hatch cover
on my 19' Bayliner with an I/O Volvo Penta. The cover is at the
end of the boat, and is 6.5' long, and about a foot wide.
Since the boat is an '85, this piece has taken some wear, and
whatever wood composite is inside the vinyl, it is weakened, and
could use some reinforcement. It is all vinyl covered, so I don't
think the inside piece can be replaced, but I'm not sure.
The strip hinge screws can't all hold their secureness in the wood,
although the hinge still works.

I could put screws all the way through from the top, but the heads
would be exposed, and that would change the smooth vinyl surface.
Another idea is to cut a piece of luan plywood, and reinforce the
whole cover piece.

Anybody ever have the same problem, and fix it? Thanks.

 

[45Auto]

Re: How to reinforce rear hatch cover?

All the vinyl trim panels on my Bayliner were just vinyl stapled over cheap plywood. Pull the staples, peel the vinyl off and use the old wood for a pattern if there's enough left of it.

 

[salty87]

Re: How to reinforce rear hatch cover?

i've replaced mine before, re-used the old vinyl. it was pretty easy although a little messy by the time you seal the plywood. a friend of mine paid a shop instead, was about $250 to re-use his vinyl and only replace the ply.

 

[Mike722]

Re: How to reinforce rear hatch cover?

You should use marine grade plywood. Not all lumber yards carry it in stock and it is more expensive.

 

[Lone Duck]

Re: How to reinforce rear hatch cover?

On covered hatch covers and the like I use treated plywood.

 

[mickjetblue]

Re: How to reinforce rear hatch cover?

Well, I have taken out about half of the staples, as there are hundreds
of them holding the vinyl down. The existing plywood piece is definitely
rotted from being soaking wet. I can't figure out how all that moisture
got into the wood. There are no rips in the vinyl. Maybe sweating from
temperature changes and being over the engine area. This will be a
nice winter project. The piece lasted over 22 years, so that that's not bad.

Thanks for the tips.

 

[45Auto]

Re: How to reinforce rear hatch cover?

I replaced a lot of wood on my Bayliner in 2000 (under the seats, etc). I used regular plywood sealed with 2 heavy coats of spar varnish. All of it still looked like new when I sold the boat this summer.

 

[Old Salt Oz]

Re: How to reinforce rear hatch cover?

If you plan to replace the ply it will need proper sealing, a couple of coats of epoxy resin would be a minimum, the a coat of paint to protect it UV light.

You can save some dollars by using construction (outdoor) ply, the glue is much the same as marine ply but construction ply will have small voids inside left by imperfections (wood Knots and the like), Marine ply should have no voids at all.